Another day, another brief step forward in catching up on my backlog of train simulator blog posts before I inevitably fall well behind where I actually am with the project again. A few days ago, I showed one of the panels (TPWS) going into my train simulator; now, here's how I am prototyping the complete dashboard section of my simulated UK Class 80x containing that panel. Read more in the complete blog post: Train Simulator Controller: Dashboard Prototyping, Part 3

Train Simulator Controller: Dashboard Prototyping, Part 3



In two previous blog posts, I showed how I determined the dimensions of the center of the dashboard and created a cardboard prototype, and then how I turned the cardboard version into a CAD model and laser-cut hardboard components. Next, I needed to finish gluing the components of the hardboard version together, add the instruments and controls, mark the buttons, and finally test it. Most of the instruments and controls had already been individually connected to my ubiquitous CAN bus transceivers, including with specialized daughterboards where needed.

At the end of the previous dashboard assembly blog post, I had begun gluing the crenellated panels of the center dashboard console together, and quickly completed this process, including gluing four thin hardboard supports onto the back to hold the console up at the correct angle. I learned a few lessons about working with hardboard, especially that its thinness makes edge-to-surface glued joints fragile.



Next, I explored adding markings to the buttons, starting with the laser-cut plywood door controls that geekboy1011 and I had created over a year ago, then proceeding to the status LEDs on the left of this center console (Line Volt, VCB, safety system isolation, and ADD). These markings make the function of the buttons more instantly recognizable, especially when I haven’t yet applied text labels underneath buttons and indicators.





With this center dashboard console prototype constructed and most of the controls connected, I took a Class 801 for a snowy ride up the ECML in Train Simulator Classic:

[Video:] https://z80.me/blog/tsc-dash-prototype-3/img/cancel_aws_short.mp4

With the center console of my train simulator built, over the following month and a half I rapidly modeled and fabricated prototypes of the four other panels. As always, I've documented the process in my latest blog post: Train Simulator Controller: Dashboard Prototype Part 4, All the Panels.

Train Simulator Controller: Dashboard Prototype Part 4, All the Panels



Having nailed down the process of turning my cardboard experiments and sketches into hardboard prototypes as described in my previous post, I wanted to see the hardboard versions of the four remaining panels constructed. I have not yet completed the electronics for all of these panels, or even collected all the buttons and switches that I need, but with panels prototyped, I could be unblocked to pursue two parallel paths: replacing the hardboard prototypes with sturdier, thicker wood or metal panels, and continuing to collect the additional components I would need. Therefore, I next needed to estimate dimensions, compute angles, and create CAD designs of the next four panels:

• The right-hand panel, containing the right side door controls, electric and diesel control, horn, GSM-R DCP, and other controls.
  
• The left side door controls.
  
• The CCTV monitors
  
• The left-hand panel containing headlight, cab light, and HVAC controls

In late December, the laser-cut and CNC-milled panels and supports arrived, and I wasted no time gluing it all together to see just how big the final simulator will be. In a recent video from UK train company LNER, railway historian Tim Dunn tried out an official LNER Class 801 simulator, and commented “[you] could sell these [simulators …] imagine going to my boyfriend saying, ‘Hi, darling. I’ve got a new train simulator. This is taking up the entire bedroom, BTW.’” That sentiment hit uncomfortably close to home, but I’m hopeful that my current modular design will at least allow this simulator to be disassembled and stored easily: the largest piece will be half of the supporting table, a flat sheet that fits inside a 1.5 meter x 0.5 meter rectangle.

Next up, I will fabricate the desk that these components sit on, while continuing to fabricate the control boards for the controls on these panels. Look for more updates soon!

Over the past few months, my focus has been on the physical layout and panels of my simulator, into which I've been placing all the buttons, controls, and instruments I previously constructed. I created a cardboard prototype of the center panel of the simulator last year, and at the end of the summer, converted it to a sturdier hardboard version. This first of the five physical panels of the Class 80x dashboard sat on my existing wooden desk for the past few months, very occasionally used for train simulation, but mostly for a combination of software development and as a physical reminder of the project. Notably, it is also only panel that fit on my existing desk in front of my monitor, and even so was extending half off of the desk. My keyboard and mouse barely fit on the amount of desk left, and my heavy CODE keyboard in particular took a few painful headers. Therefore, I needed to build a proper table onto which I could mount all of the panels; here's how I did it. As usual, the full post with all the images is on my blog.

Train Simulator Controller: Simulator Takes Shape with Custom Table



A custom table was necessary to support or partially support the five modules of the Class 80x dashboard, allowing them to surround me in a replica of the real Class 80x cab. While at intermediate points in the project I have considered a simpler simulator merely paying tribute to the Class 80x (and other trains such as the Class 125 Intercity / HST), I eventually refused to settle for anything less than my best effort to precisely replicate a Class 80x, which looks something like this:



The first step was figuring out how to properly house the dashboard modules I’ve built. Since I had designed each of the five panels or modules of the dashboard to precisely fit against each other, it was relatively straightforward to project the footprint of each panel down onto a flat surface. As an additional complication, several of the panels have instruments that are deep enough behind the panel that when the given panel is canted backwards, the back of the instrument protrudes through the table, so I needed to add cutouts for these instruments. And I live in a small space, so I needed a dedicated but only semi-permanent table.

My solution is a plywood table that attaches securely but removably to my existing desk with a series of clamps, and is supported at the opposite edge by two adjustable-height IKEA table legs. This way, the table could be easily removed when I want to free up space. But it also needed to be sturdy enough to handle the weight and complexity of the simulator modules.

Constructing the Table
The complex shape of the prototype, including the cutouts, meant that the table’s edges needed to be precisely cut to follow the complex, angled shape of the train’s real dashboard. Therefore, I picked an easily manipulated but strong material for the table: plywood. The table was built in two halves to make cutting and transportation easier, cut from two 2’x4’ sheets of sanded plywood. After laying out the measurements and drafting the requisite CAD drawing, I used a jigsaw to carefully cut the shape of the table. This took time, as the edges of the table needed to follow precise angles and curves to match the Class 80x design. Once the cutting was complete, I had the two halves ready for assembly. I am at best an amateur woodworker, so I expect that this table is a first draft that I hope to recreate more professionally in the future.



Finishing Touches
The next step was adding the legs and clamps, then attaching the two halves of the table together. The legs were simply screwed into the underside of the two halves at the farthest possible point from the clamps, to minimize the unsupported area of the table surface. This will allow me to adjust the height during use to match the height of my sit-stand desk. I attached the clamps into purpose-cut notches at the edge of the table, then used wood glue and a metal mending plate underneath securely join the two halves together.



Setting Up the Dashboard Modules
Once the table was assembled and securely attached to the desk, it was time to place the dashboard panels on top. I wanted to make sure everything fit perfectly, so I placed each of the five dashboard panels in their designated spots. First I checked that the center panel fit.



I then placed the remaining panels on top, and am evaluating if any of the dimensions will need to be adjusted if I construct a second version of the table.



Current State and What’s Next

With the table and dashboard modules in place, I’m thrilled with how it’s turning out. The semi-permanent design works well for my setup, and I’m able to adjust and store the table with minimal hassle. The most exciting part is how immersive the simulated cab feels.

Next up, I will be wiring up even more of the buttons and controls, and there are still some instruments and buttons I need to source. I also need to finalize my plans for the four LCD panels that fit the large blank areas and open rectangles in the current design. Stay tuned for more updates as I continue to develop the simulator!

Holy smokes that dashboard is looking incredible, you are making great progress with this Kerm! I look forward to the next Trains stream

Thanks, Michael2_3B, I appreciate it! It's been a long project of small fiddly bits, so seeing the big components finally coming together into something more obviously train-shaped is quite gratifying for me. I'm planning to try a train stream tonight, but I'll see if time permit.

I've published a little video taking my simulator for a spin; more soon, I'm sure!